Adapter for powered surgical devices

ABSTRACT

An adapter assembly for selectively interconnecting a surgical end effector including at least one axially translatable drive member and a powered actuator device including at least one rotatable drive shaft is provided. The adapter assembly includes an actuation shaft configured to convert rotation of a first drive shaft of the powered actuator device into an axial translation of a first drive member of the surgical end effector. The adapter assembly further includes an elongate tube configured to convert rotation of a second drive shaft of the powered actuator device into an axial translation of a second drive member of the surgical end effector. The actuation shaft is disposed within the elongate tube, and the actuation shaft and the elongate tube translate axially independent of each other.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation application of U.S. patent application Ser. No. 15/002,489, filed on Jan. 21, 2016, which is a continuation application of U.S. patent application Ser. No. 13/621,859, filed on Sep. 18, 2012, now U.S. Pat. No. 9,282,963, which is a continuation application of U.S. patent application Ser. No. 13/216,330, filed Aug. 24, 2011, now U.S. Pat. No. 8,292,150, which claims the benefit of and priority to U.S. Provisional Application No. 61/409,132 filed on Nov. 2, 2010. The entire contents of each of the foregoing applications are incorporated by reference herein.

BACKGROUND 1. Technical Field

The present disclosure relates to a surgical device and, more particularly, to an adapter assembly for selectively interconnecting a surgical end effector and a powered actuator device.

2. Background of Related Art

A number of proprietary drive systems for operating surgical devices that clamp tissue between opposing jaw structures and then join tissue by surgical fasteners have been developed by various surgical device manufacturers. Many of the existing surgical end effectors used in performing, for example, endo-gastrointestinal anastomosis procedures, end-to-end anastomosis procedures and transverse anastomosis procedures, typically require linear driving force in order to be operated.

Generally, the stapling operation is effected by cam bars that travel longitudinally through the staple cartridge and act upon staple pushers to sequentially eject the staples from the staple cartridge. Such cam bars are typically actuated by a trigger squeezed by an operator or a powered actuator device that provides rotary motion to deliver driving force. In the case of a powered actuator device that uses rotary motion to deliver driving force the rotary motion is not compatible with surgical end effectors that require linear driving force.

As such, in order to make the linear driven surgical end effectors compatible with the powered actuator devices that use rotary motion to deliver driving force, adapter assemblies that convert the output features of the powered actuator devices to match the work input requirements of end effectors are required.

SUMMARY

In accordance with an embodiment of the present disclosure, there is provided an adapter assembly for selectively interconnecting a surgical end effector and a powered actuator device. The adapter assembly includes a first drive converter assembly configured to convert a rotation of a first drive shaft of the powered actuator device into an axial translation of a first drive member of the surgical end effector and a second drive converter assembly configured to convert a rotation of a second drive shaft of the powered actuator device into an axial translation of a second drive member of the surgical end effector. The first drive converter assembly is at least partially disposed within the second drive converter assembly, wherein the first drive converter assembly and the second drive converter assembly are configured to rotate and translate independent of each other.

The adapter assembly may further include first and second drive rods configured to be coupled with the rotatable first and second drive shafts of the powered actuator device, respectively. The first drive rod engages the first drive converter assembly and the second drive rod engages the second drive converter assembly.

The first and second drive rods may each include a pinion gear portion. The first drive converter assembly may include an actuation shaft defining a worm gear portion. The first drive rod supports a pinion gear portion, wherein the worm gear portion of the actuation shaft engages the pinion gear portion of the first drive rod, whereby rotation of the first drive shaft of the powered actuator device rotates the pinion gear portion of the first drive rod to effectuate axial translation of the actuation shaft which in turn axially translates the first drive member of the surgical end effector.

Similarly, the second drive converter assembly may include an elongate tube defining a worm gear portion. The second drive rod supports a pinion gear portion, wherein the worm gear portion of the elongate tube engages the pinion gear portion of the second drive rod, whereby rotation of the second drive shaft of the powered actuator device rotates the pinion gear portion of the second drive rod to effectuate axial translation of the elongate tube which in turn axially translates the second drive member of the surgical end effector.

The first and second drive rods may be flexible and capable of transmitting rotational forces. In addition, a distal end of the adapter assembly may be configured for a selective, detachable fitting with the surgical end effector.

In accordance with another aspect of the present disclosure, there is provided a surgical device including a powered actuator device including at least two rotatable drive shafts, a surgical end effector including at least two axially translatable drive members and an adapter assembly including a first drive converter assembly and a second drive converter assembly. The first drive converter assembly is configured to convert rotation of a first drive shaft of the powered actuator device into an axial translation of a first drive member of the surgical end effector. The second drive converter assembly is configured to convert rotation of a second drive shaft of the powered actuator device into an axial translation of a second drive member of the surgical end effector, wherein the first drive converter assembly is at least partially disposed within the second drive converter assembly.

The adapter assembly may further include first and second drive rods configured to be operatively coupled with the rotatable first and second drive shafts of the powered actuator device, respectively. The first drive rod engages the first drive converter assembly and the second drive rod engages second drive converter assembly.

The first and second drive rods may each include a pinion gear portion. Moreover, the first drive converter assembly may include an actuation shaft defining a worm gear portion, wherein the first drive rod supports a pinion gear portion. The worm gear portion of the actuation shaft engages the pinion gear portion of the first drive rod, whereby rotation of the first drive shaft of the powered actuator device rotates the pinion gear portion of the first drive rod to effectuate axial translation of the actuation shaft which in turn axially translates the first drive member of the surgical end effector.

Similarly, the second drive converter assembly may include an elongate tube defining a worm gear portion, wherein the second drive rod supports a pinion gear portion. The worm gear portion of the elongate tube engages the pinion gear portion of the second drive rod, whereby rotation of the second drive shaft of the powered actuator device rotates the pinion gear portion of the second drive rod to effectuate axial translation of the elongate tube which in turn axially translates the second drive member of the surgical end effector.

The first and second drive rods may be flexible and capable of transmitting rotational forces. In addition, a distal end of the adapter assembly may be configured for a selective, detachable fitting with the surgical end effector.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing objects, features and advantages of the disclosure will become more apparent from a reading of the following description in connection with the accompanying drawings, in which:

FIG. 1 is a perspective view of a surgical device including an adapter assembly according to an embodiment of the present disclosure;

FIG. 2 is a perspective view of the surgical device of FIG. 1, illustrating the potential use with various surgical end effectors;

FIG. 3 is a perspective view of a right angled linear cutter/stapler end effector for use with an adapter assembly according to an embodiment of the present disclosure;

FIG. 4 is a perspective view of an adapter assembly according to an embodiment of the present disclosure having a surgical end effector connected thereto;

FIG. 5 is an enlarged perspective view of the adapter assembly of FIG. 4 shown with an outer tube removed therefrom; and

FIG. 6 is an enlarged perspective view of the adapter assembly of FIG. 5 illustrating an independent axial translation of an actuation shaft and an inner tube thereof.

DETAILED DESCRIPTION OF EMBODIMENTS

Embodiments of the presently disclosed adapter assemblies for surgical devices are described in detail with reference to the drawings, in which like reference numerals designate identical or corresponding elements in each of the several views. In the drawings and in the description that follows, the term “proximal,” as is traditional, will refer to the end of the stapling apparatus which is closest to the operator, while the term “distal” will refer to the end of the apparatus which is farthest from the operator.

Referring now to FIG. 1, there is disclosed a powered surgical instrument generally referred to as 10. In the interest of brevity, this disclosure will focus primarily on a mechanical adapter assembly 100 for selectively interconnecting a surgical end effector and a powered actuator device 20. For a detailed description of the construction and operation of exemplary powered surgical instrument 10 for use with adapter assembly 100, reference may be made to U.S. Patent Application Publication No. 2007/0023477, the entire content of which is incorporated herein by reference.

With reference to FIGS. 1-3, powered surgical instrument 10 generally includes a powered actuator device 20 and mechanical adapter assembly 100 selectively interconnecting any one of surgical end effectors 40, 50, 60, 70 and powered actuator device 20. Any one of end effectors 40, 50, 60, 70 may be releasably secured to a distal end of adapter assembly 100. Each end effector 40, 50, 60, 70 includes a cartridge assembly housing a plurality of surgical fasteners or staples and an anvil assembly movably secured in relation to the cartridge assembly. Powered actuator device 20 includes a housing, at least one drive motor, at least one energy source for powering the at least one drive motor, and at least one rotatable drive shaft connected to the at least one drive motor. In use, the actuation of the drive motor results in an actuation of an end effector 40, 50, 60, 70 attached thereto, to apply staples to tissue and to optionally cut tissue.

With reference to FIGS. 4, 5 and 6, an adapter assembly in accordance with an embodiment of the present disclosure is shown generally as 100. As shown in FIGS. 4-6, adapter assembly 100 is operatively connected to a distal end of powered actuator device 20, and surgical end effector 50 is selectively coupled to a distal end of adapter assembly 100. However, adapter assembly 100 is configured to operatively interconnect any one of a number of surgical end effectors to powered actuator device 20, as seen in FIG. 2. For example, adapter assembly 100 may operatively interconnect and couple powered actuator device 20 to an endo-gastrointestinal anastomosis end effector 40 or a transverse anastomosis end effector 60, both of which require linear driving force.

Each of end effectors 40, 50, 60 includes an axially translatable drive member to fire end effectors 40, 50, 60 to expel staples contained in the cartridge assembly for formation against the anvil assembly and/or to actuate a knife blade along the staple line. End effectors 40, 50, 60 may include an additional axially translatable drive member that is configured to open and close the jaw assemblies by approximating at least one of the anvil assembly and the cartridge assembly to and away from one another. The additional axially translatable drive member may also be configured to cause articulation of end effectors 40, 50, 60.

Adapter assembly 100 may be configured to operatively interconnect with a surgical end effector requiring a linear driving force, but may also be adaptable to be operatively coupled to an end effector requiring a rotational driving force for an operation thereof, such as, for example, a right angled linear cutter/stapler end effector 70, as shown in FIG. 3. Right angled linear cutter/stapler end effector 70 includes a rotatable drive member for firing end effector 70 to expel staples contained in the cartridge assembly for formation against the anvil assembly. End effector 70 may include additional rotatable drive members to actuate a knife blade along the staple line and/or to open and close the jaw assemblies by approximating at least one of the anvil assembly and the cartridge assembly to and away from one another.

With reference still to FIGS. 4-6, a detailed description of the construction and operation of adapter assembly 100 is provided. Adapter assembly 100 includes a tube housing 110 configured to house the components of adapter assembly 100 and dimensioned such that tube housing 110 may pass through a typical trocar port, cannula or the like. Tube housing 110 includes a distal end portion 110 a that is operatively coupled to end effector 50 and a proximal end portion 110 b that is coupled to powered actuator device 20.

In particular, as seen in FIGS. 5 and 6, adapter assembly 100 further includes a drive coupling assembly 112 at a proximal end portion thereof, which operatively couples adapter assembly 100 to powered actuator device 20. Drive coupling assembly 112 includes rotatably supported and distally extending first and second proximal drive shafts 116, 118, respectively. Proximal drive shafts 116, 118 may be made flexible to act as shock absorbers allowing for reduced peak loads, yet sufficiently rigid to transmit rotational forces. First and second proximal drive shafts 116, 118 each include at a proximal portion thereof a tapered neck portion (not shown) having a non-circular cross-sectional profile, e.g., square shaped. Each of first and second proximal drive shafts 116, 118 is provided with a biasing means (not shown) disposed about the respective neck portion and a sleeve (not shown) disposed proximal of the biasing means. The sleeves each define a bore having a cross-sectional profile that corresponds to that of the neck portion of proximal drive shafts 116, 118. The distal ends of the first and second drive shafts of powered actuator device 20 include coupling cuffs 120, 122, each defining a recess 120 a, 122 a corresponding to the non-circular cross-sectional profile of the neck portion of proximal drive shafts 116, 118. Coupling cuffs 120, 122 of actuator device 20 engage the proximal end portions (not shown) of proximal drive shafts 116, 118 (wherein each proximal end portion of the proximal drive shafts 116, 118 has a non-circular cross-sectional profile for engaging respective recess 120 a, 122 a of coupling cuffs 120, 122), whereby rotation of drive shafts (not shown) of powered actuator device 20 results in concomitant rotation of coupling cuffs 120, 122 and concomitant rotation of first and second proximal drive shafts 116, 118.

With continued reference to FIGS. 5 and 6, adapter assembly 100 further includes first and second drive converter assemblies 130, 140. Each drive converter assembly 130, 140 is configured to convert rotation of respective first and second drive shafts of powered actuator device 20 and concomitant rotation of respective first and second proximal drive shafts 116, 118 into axial translation of respective drive members of end effector 50.

The first drive converter assembly 130 includes an actuation shaft 132 translatably supported for axial reciprocation within an inner tube 142 of drive converter assembly 140 by any number of appropriately positioned and sized bearings and/or bushings (not shown). The coaxial relationship of actuation shaft 132 and inner tube 142 allows for axially rotational displacement thereof without adverse end effector 50 actuation or spatial conflict therebetween. Actuation shaft 132 includes a worm-gear portion 132 a at a proximal end region of actuation shaft 132 and a distal end portion 132 b defining a connection member 136 configured for selective engagement with an axially translatable drive member of end effector 50. First drive converter assembly 130 further includes a pinion or worm gear portion 134 provided at a distal end portion of first proximal drive shaft 116. Pinion gear portion 134 engages worm gear portion 132 a at a proximal end region of actuation shaft 132.

In operation, as seen in FIGS. 5 and 6, the activation/rotation of a first drive shaft (not shown) of powered surgical device 20 results in concomitant rotation of first proximal drive shaft 116 of adapter assembly 100. As first proximal drive shaft 116 is rotated, first proximal drive shaft 116 causes rotation of pinion gear portion 134. Since pinion gear portion 134, at a distal end portion of first proximal drive shaft 116, engages worm gear portion 132 a of actuation shaft 132, rotation of pinion gear portion 134 causes axial translation of actuation shaft 132. It is contemplated that the actuation shaft 132 is supported by any number of appropriately positioned and sized bearings and bushings (not shown) that enable axial translation in the direction of “A” as shown in FIG. 6. Accordingly, with connection member 136 of actuation shaft 132 connected to a first drive member of end effector 50, axial translation of actuation shaft 132 causes concomitant axial translation of the first drive member of end effector 50 to effectuate an operation and/or function thereof, such as, for example, firing of the end effector 50.

Upon completion of the operation and/or function of the first drive member of end effector 50, e.g., firing of end effector 50, actuation shaft 132 may be retracted to its initial position for subsequent operation thereof. The first drive shaft (not shown) of powered surgical device 20 is reactivated causing rotation thereof in the direction opposite to that when actuation shaft 132 was axially translated in the distal direction. The concomitant rotation of first proximal drive shaft 116 of adapter assembly 100 causes rotation of pinion gear portion 134. Pinion gear portion 134 engages worm gear portion 132 a of actuation shaft 132 and causes axial translation of actuation shaft 132 in a proximal direction until actuation shaft 132 reaches the initial position.

With continued reference to FIGS. 5 and 6, second drive converter assembly 140 includes an inner tube 142 rotatably supported by rotary plates 144 or by any number of appropriately positioned and sized bearings or bushings (not shown) for axial reciprocation of inner tube 142 within tube housing 110. Inner tube 142 includes a worm-gear portion 142 a at a proximal end region of inner tube 142 and a distal end portion 142 b disposed at a distal end of tube housing 110. Second drive converter assembly 140 further includes a pinion or worm gear 138 provided at a distal end portion of second proximal drive shaft 118. Worm-gear portion 142 a of inner tube 142 engages pinion gear 138 for axial reciprocation of inner tube 142 within tube housing 110.

In operation, as seen in FIGS. 5 and 6, the activation/rotation of a second drive shaft (not shown) of powered surgical device 20 results in concomitant rotation of second proximal drive shaft 118 of adapter assembly 100. As second proximal drive shaft 118 is rotated due to rotation of the second drive shaft of powered actuator device 20, pinion gear 138 of second drive converter assembly 150 is caused to be rotated. Since pinion gear 138, at a distal end portion of second proximal drive shaft 118, engages worm gear portion 142 a of inner tube 142, rotation of pinion gear portion 138 causes axial translation of inner tube 142 independently of actuation shaft 132, in the direction of arrow “A” as shown in FIG. 6. Accordingly, as inner tube 142 is translated axially, with the distal end of inner tube 142 connected to a second drive member of end effector 50, inner tube 142 causes concomitant axial translation of the second drive member of end effector 50 to effectuate an additional operation thereof, such as, for example, articulation of the end effector and/or approximation of the pair of jaws, independent of the operation effected by actuation shaft 132.

Upon completion of the operation and/or function of the second drive member of end effector 50, e.g., articulation of end effector 50 and/or approximation of the pair of jaws, inner tube 142 may be retracted to its initial position for subsequent operation thereof. The second drive shaft (not shown) of powered surgical device 20 is reactivated causing rotation thereof in the direction opposite to that when inner tube 142 was axially translated in the distal direction. The concomitant rotation of second proximal drive shaft 118 of adapter assembly 100 causes rotation of pinion gear portion 138. Pinion gear portion 138 engages worm gear portion 142 a of inner tube 142 and causes axial translation of inner tube 142 in a proximal direction until inner tube 142 reaches the initial position.

Actuation shaft 132 is dimensioned to be concentrically arranged within inner tube 142 which allows for a compact design of adapter assembly 100 and independent coaxial translation of actuation shaft 132 with respect to inner tube 142. Actuation shaft 132 may further include a pair of flanges (not shown) extending radially, so that the pair of flanges restrict the range of axial translation of actuation shaft 132 in conjunction with an inwardly extending flange (not shown) formed within inner tube 142, whereby a proximal end of actuation shaft 132 is prevented from being driven into drive coupling assembly 112 and/or from distally disengaging pinion gear 134 of first proximal drive shaft 116. Moreover, the placement of the flanges may be tailored to meet the needs of a particular end effector to take into account, e.g., the required travel distance of the particular axially translatable drive member of the surgical end effector.

Similarly, inner tube 142 may further include radially extending flanges (not shown) such that inner tube 142 reciprocates axially inside tube housing 110 within a predetermined ranged. Under such design, inner tube 142 is prevented from being driven distally into pinion gear 134 on first proximal drive shaft 116 and from distally disengaging pinion gear 138 on second proximal drive shaft 122. Moreover, such design allows inner tube 142 to translate only the distance required to effectuate an operation of the drive member of end effector 50.

In accordance with the present disclosure, it is contemplated that the adapter assembly 100 may incorporate a transmission or gearing portion to optimize the rotational speed and torque or the linear speed and force to control and manipulate specific end effectors. Furthermore, the pitch and helix angle of the worm gear can be configured to provide additional speed and/or force refinements as needed.

It is further contemplated that the proximal and distal ends of adapter assembly 100 may be operatively coupled to powered actuator device 20 and any one of end effectors 40, 50, 60, 70, respectively, using a variety of attachment features, such as, for example, a bayonet coupling, latch, detent or snap-fit. In addition, adapter assembly 100 may include a lock mechanism (not shown) configured to fix the axial position and radial orientation of actuation shaft 132 for the connection and disconnection of end effectors 40, 50, 60, 70 thereto. Still further, axial rotation of the entire tube housing 110 can be accomplished by engaging rotary power from the power actuator (if available) or by manually turning the tube housing.

It will be understood that various modifications may be made to the embodiments disclosed herein. Therefore, the above description should not be construed as limiting, but merely as exemplifications of preferred embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended thereto. 

1-17. (canceled)
 18. A surgical instrument comprising: a surgical end effector including a first drive member and a second drive member; an actuator device including: a power source; at least one motor electrically coupled to the power source; and a first drive shaft and a second drive shaft, each of which is actuated by the at least one motor; an actuation shaft configured to convert a rotation of the first drive shaft into an axial movement of the first drive member; and an elongate tube configured to convert a rotation of the second drive shaft into an axial movement of the second drive member, wherein the actuation shaft is at least partially disposed within the elongate tube and the actuation shaft and the elongate tube are rotatably and axially movable relative to each other.
 19. The surgical instrument of claim 18, further comprising: a first drive rod configured to engage a first drive shaft of a powered actuator device and the actuation shaft; and a second drive rod configured to engage a second drive shaft of a powered actuator device and the elongate tube.
 20. The surgical instrument of claim 19, wherein each of the first and second drive rods includes a pinion gear portion.
 21. The surgical instrument of claim 20, wherein the actuation shaft includes a worm gear portion configured to engage the pinion gear portion of the first drive rod.
 22. The surgical instrument of claim 20, wherein the elongate tube includes a worm gear portion configured to engage the pinion gear portion of the second drive rod.
 23. The surgical instrument of claim 19, wherein the first and second drive rods are flexible and are configured to transmit rotational forces.
 24. A surgical instrument comprising: a surgical end effector including a first drive member and a second drive member; a powered actuator device including a first drive shaft and a second drive shaft; and an actuation shaft configured to convert a rotation of the first drive shaft into an axial movement of the first drive member; and an elongate tube configured to convert a rotation of the second drive shaft into an axial movement of the second drive member, wherein the actuation shaft is at least partially disposed within the elongate tube and the actuation shaft and the elongate tube are rotatably and axially movable relative to each other.
 25. The surgical instrument of claim 24, further comprising: a first drive rod configured to engage the first drive shaft and the actuation shaft; and a second drive rod configured to engage the second drive shaft and the elongate tube.
 26. The surgical instrument of claim 25, wherein each of the first and second drive rods includes a pinion gear portion.
 27. The surgical instrument of claim 26, wherein the actuation shaft includes a worm gear portion configured to engage the pinion gear portion of the first drive rod, such that rotation of the first drive shaft of the powered actuator device rotates the pinion gear portion of the first drive rod to effectuate axial movement of the actuation shaft, which in turn, axially moves the first drive member of the surgical end effector.
 28. The surgical instrument of claim 26, wherein the elongate tube includes a worm gear portion configured to engage the pinion gear portion of the second drive rod, such that rotation of the second drive shaft of the powered actuator device rotates the pinion gear portion of the second drive rod to effectuate axial movement of the elongate tube, which in turn, axially moves the second drive member of the surgical end effector.
 29. The surgical instrument of claim 25, wherein the first and second drive rods are flexible and are configured to transmit rotational forces.
 30. The surgical instrument of claim 24, wherein the surgical end effector includes an anvil assembly and a cartridge assembly having at least one tissue fastener.
 31. The surgical instrument of claim 30, wherein the first drive member is configured to eject the at least one tissue fastener from the cartridge assembly in response to the axial movement of the first drive member.
 32. The surgical instrument of claim 30, wherein the second drive member is configured to move the anvil assembly and the cartridge assembly relative to each other in response to the axial movement of the second drive member. 